The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

HL – LHC WBS & more

Project Coordination Office supporting the HL Project

Isabel Bejar Alonso, Joao Carlos Batista Lopes, Claudia Parente

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Why we are having this presentation?

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Three main messages•WBS why it is so important and why will be

used as starting point for most project processes• Standards – what tools we will have to ensure

that we use the “right” ones while preparing the design files• Safety – how to integrate it from the beginning

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Modifying at least 1.2 Km of an existing machine

3000 fb-1 in 10 yearsLimited pile up : 140 5 1035 levelled

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Modifying at least 1.2 Km of an existing machine

Cryogenics

Collimation

IR Magnets

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And modifying means …• New systems • New equipment for existing systems•Modifications to the present systems to adapt

to the new equipment/system• “Consolidation” (even if handled outside HL)• Dismantling and elimination of equipment

replaced

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WBS some conceptsDefinition“The Work breakdown structure is a deliverable-oriented hierarchical decomposition of the work to be executed by the project team to accomplish the project objectives and create the required deliverables. The WBS organizes and defines the total scope of the project” (PMBOK)

Why- To ensure a clear definition and communication of project scope

- To have a baseline for planning, costing, scheduling, …ing.

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WBS some concepts - DeliverableDefinition“Any unique and verifiable product, result, or capability to perform a service that must be produced to complete a process, phase or project. ” (PMBOK)

ImportantA deliverable is not a task or an activity. You will need those to obtain the deliverable.

What at CERN we call Work packages is not what the PMBOK calls Work Packages as they are not the lowest level in the WBS.

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Starting pointLS2 - 1 y (14 months access) LS3 - 2 y (26 months access)

US1 US2 Cost (MCHF) In kind LS2 LS3 LS3 LS3 in part

P4 new cryoplant Y 15H SC link P7 Y 5IR (IT,D1, TAS) % Y 210 YESP1-P5 cryoplant % Y 75SC link (EPC&DFBX on surface) % Y 40Collimators IR Y 10Collimators MoGr % Y 15Collimators for INJ &TCLA Q4/Q5) Y 5DS cryocoll.(11T) P2 Y 20 395LRBB comp.wires Y 10DS cryocoll.(11T) P7 Y 25DS cryocoll (11 T) P1-P5 Y 40SC link (EPC&DFB on surface) for MS Y 20 95MS new layout (P1-P5) and Q5 in P6 Y 30 YESMachine & Magnet QPS (Availability) Y 25CC cavity P1-P5 Y 95 YESSCRF 2nd Harmonic YCrystal Coll Y ? YES ?Halo control (e-lens) Y ? YESHigh Band Feedback System Y ? 150Studies 10Other systems (Studies, Vacuum, Diagnostics, Remote handling 30Infrastructure, Logistics, Integration,Installation HWC 130 170

And not only

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To be done for every existing system installedIdentify the changes included in the HL scope and prepare a list of deliverables

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To be done for every deliverableEvery deliverable shall be linked to an LHC system or declared as a new LHC system /subsystem (ex. Halo control)

Every deliverable is assigned to a HL WP.

New HL WPs will be created if required

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As a collaborative process

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As a structured process

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Supported by guides and templates

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WBS as the starting point for the …ing

DELIVERABLES TASKS & ACTIVITIES

SCHEDULE

RESOURCESBUDGET

MILESTONES

EVM

RISK RISK REGISTER …

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Supporting the Technical processes

performance and interface requirements … but not only

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From Concept to Design

Once finalized the Conceptual phase we will enter the Implementation phase where the functional specifications will become design files for components that will be fabricated.

To the existing performance, and interface requirements we will have to add “design constraints”

“Design constrains” hierarchyRules

&Regulations

Codes and standards

Specific technologies and methods

Safety Quality Technical

Called sometimes “constrains”; Safety, Quality and Technical requirements have to be added to the performance and interface requirements identified during the conceptual phase

Rules&

Regulation

s

Codes and standards

Codes & StandardsAdvantages• Increased confidence on the

Quality of equipment• Increase of equipment’s reliability

and availability• Minimization of risks and costs

• Ensures Compliance with CERN Safety rules/EU regulations • Presumption of conformity with the

Essential Safety Requirements of EU directives (whenever applicable) by using Harmonized Standards

DisadvantagesCodes and standards are not (yet, or completely) cost free or Global market oriented• 55% and 70% of all European

standards adopted by CEN and CENELEC are technically equivalent or identical to ISO and IEC standards, respectively

• Unified approach still to be extended to other standards development organizations namely in the US.

Rules&

Regulations

Codes and standards

Codes & StandardsReliability and Availability

Working in a Radioactive environment

Minimization of risks and costs

Components Designed and built around the globe

But how to identify the applicable ones

Standards evolution since the LHC

Two examples:• Cold masses (dipoles)• Vacuum vessels

Do not reuse your old specs ….

IT-2544 / Vacuum vessels

IT-2799 / CM dipoles

LHC PRESENTLY

Standards architecture ICSManufacturing

engineering

Welding processes

Welded joints

* based on the International Classification of Standards (ICS)

Brazing and soldering

A non-exhaustive overview of some fields and their corresponding groups and sub-groups*

Welding, brazing and soldering

Metallurgy

Iron and steel products

Iron and steel castings

Iron and steel forgings

Steels for pressure purposes

Testing of metals

Mechanical testing of metals

Non-destructive testing of metals

Electrical engineering

Superconductivity and conducting

materials

Insulating materials

Magnetic materials

FIELDS

GROUPS

SUB-GROUPS

The complete map contains the groups that were used in old specs + what we think you could need

Standards – Present scenarioManufacturing

engineering

Welding processes

Welding joints

Iron and steel products

Mechanical testing of metals

Non-destructive testing of metals

Iron and steel castings

Metallurgy

Fusion welding

Examples

Identification with the WPE the interesting subgroups

Welding and allied processes - Fusion weldingSpecified in its superseded /replaced versionSpecified in its valid version

Approval testing of welders

Iron and steel castings

Specified in its superseded/replaced versionSpecified in its valid version

Harmonized standards 89/106/EEC - Construction products (CPD/CPR)

Mechanical testing of metals

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Codes & Standards maps• A guide to identify if there is an standard that

guides you to fulfill your quality/technical/ safety requirements• A basis for benchmarking and best practices • ICS makes easier to find the equivalence in

other countries

Safety requirements

Rules&

Regulations

But how to identify the applicable ones

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Guided processWPE tasks to identify Safety requirements

Step

1 -

Iden

tifica

tion

of C

ERN

Saf

ety

rule

s &

Host

stat

e re

gula

tions

Step

2 -

Iden

tifica

tion

of th

e sy

stem

/pro

cess

Saf

ety

requ

irem

ents

Step

3- R

isk a

sses

smen

tSt

ep 4

– c

onso

lidati

on o

f Saf

ety

requ

irem

ents

PhaseInput Tasks Output

Safety form(EDMS 1095136) WPE meets PSO

DOCUMENT 1:Description the system/process identification of related hazards

WPE meets HSE correspondent

DOCUMENT 2:CERN Safety rules &

Host State regulations applicable to the system/process

WPE selects Safety requirements

Safety form(EDMS 1313236)

DOCUMENT 3 (V1):List of requirements and related Safety

checks

DOCUMENT 1

DOCUMENT 2

If required, WPE organizes risk assessment

Safety form(EDMS 1114759)

Safety guideline(EDMS 1114042) DOCUMENT 4:

Action plan with control measures

WPE consolidates Safety

requirements

DOCUMENT 3 (V1)

DOCUMENT 4

DOCUMENT 3 (V2)

To verify document 3 (V2) with PSO and HSE

System Safety file

Safety file for the detection system

System

Auxiliary system – e.g. Power supply

Electricity

System – e.g. Superconducting magnet

Pressure

ChemicalElectricity

Mechanical Radiation

Auxiliary system – e.g. Control system

Software

Electrical Safety file

Chemical Safety file

Magnetic field Safety

file

Mechanical Safety file

Radioprotection Safety file

Pressure equipment Safety file

Electrical Safety file

Control system

Safety file

Magnetic

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With roles and responsibilities identifiedHigh Luminosity Project Safety requirements

Bo

tto

m le

vel:

CER

N O

rgan

ic U

nit

,

ext

ern

al c

om

pan

ies

Inte

rmed

iate

leve

l: P

ers

on

in c

har

ge o

f

syst

em

s/p

roce

sse

s &

su

b-s

yste

ms/

pro

cess

es

Top

leve

l: P

roje

ct &

Wo

rk p

acka

ge

man

agem

en

t

Participants Responsibilities

Project Coordination

To provide system/process with compliance documents demonstrating compliance with S/PSR: S/PCD

To ensure that Project Safety requirements (PSR) are taken into account

PSO

Work package leader (WPL)

To ensure that WP Safety requirements (WPSR) are taken into account

Work Package engineer(WPE) – system/process

level

Work package engineer(WPE) – sub-system/

process level

To select from S/PSR the Safety requirements applicable to the sub-system/process: Sub-S/PSR

To provide sub-system/process with compliance documents demonstrating compliance with Sub-S/PSR:

Sub-S/PCD

Sub-S/PSR Sub-S/PCD

Service & product providers

Suppliers: e.g. raw materials

S/PSR S/PCD

To select from Sub-S/PSR the Safety requirements applicable to the Service/product: S/PSR

To provide Service/product with compliance documents demonstrating compliance with S/PSR: S/PCD

To select Safety requirements applicable to supplies

To provide supplies with compliance documents

Work package Safety file

To Identify system/process Safety requirements (S/PSR)

S/PCD

Work package phases & Safety – Roles of the Work package memebrs & HSE together

Dism

antli

ngO

pera

tion

Impl

emen

tatio

nCo

ncep

t

Work package life cycle HSE compulsory checks HSE advice & support Work Package members

Acquisition

WPL

– E

nsur

e th

at th

e Sa

fety

requ

irem

ents

are

iden

tified

and

impl

emen

ted

durin

g th

e w

ork

pack

age

life

cycl

e

Including Safety checks

Periodic inspection

Commissioning

Operation & Maintenance

Check conformity of tendering

specifications

Operation clearance

Advi

ce a

nd e

xper

t sup

port

on

Safe

ty ri

sk a

sses

smen

t, ris

k re

ducti

on a

nd ri

sk c

ontr

ol(P

rovi

ded

by a

mul

tidis

cipl

inar

y te

am o

f Saf

ety

spec

ialis

ts)

Design clearance

Functional specification

Installation

Advice on the identification of

Safety requirements

Decommissioning & dismantling

Purchasing & manufacturing

Initial inspection

WP requirements definition

Dismantling clearance

Commissioning inspection

Design

Transport & delivery

Acceptance of delivered items

WPE - Identification of the system/process Safety requirements

WPE

- Rev

iew

, im

plem

enta

tion

and

verifi

catio

n of

the

syst

em/p

roce

ss S

afet

y re

quire

men

ts

Expl

orat

ory

phas

eCo

ncep

t sta

geDe

velo

pmen

t sta

geRe

tirem

ent s

tage

ISO 15288

Prod

uctio

n st

age

Utiliz

ation

stag

e

Supp

ort s

tage

Proj

ect p

lann

ing

perio

d Pre-

proj

ect

DoE

Prec

once

ptu

al p

lann

ing

Conc

eptu

al

desig

n

Proj

ect e

xecu

tion

Prel

imin

ary

desig

nFi

nal d

esig

nCo

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Miss

ion

Acce

ptan

ce

Ope

ratio

ns

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Documentation

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What, when, where, why, …Safety file

Ope

ratio

n &

m

aint

enan

ce fi

leCo

mm

issi

onin

g fil

eIn

stal

latio

n fil

ePu

rcha

se/m

anuf

actu

ring

file

Engi

neer

ing

desi

gn fi

le

Life cycle Electrical equipment Pressure equipment Installation Use of cryogenic fluids

Engineering

· Calculation report;· Drawings of

electrical installation;

Purchasing & manufacturing

Installation

Commissioning

Operation & Maintenance

· EC declaration of conformity;

· Cable certificates;

· Records of electrical inspection;

· Acceptance test of emergency stops;

· Records of periodic inspection;

· Calculation report;· Risk assessment;· Drawings;

· Material certificate;· Welders & welding

certificates;· Records of test &

inspections;· EC declaration of

conformity

· Records of pressure tests on vessel & relief devices

· Records of periodic pressure tests

· Installation procedures;

· Operating instructions;

· Acceptance test of oxygen deficiency detectors

· Cryogenic risk assessment;

Documents provide by the work package chain: from top level to bottom level entities

Documents provide by the HSE Unit

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Conclusions & Next steps• WBS as an enabler that ensures clear definition and

communication of the project scope• Structured approach with well defined processes• Guidelines and training to ensure a common approach• Support to identify the design requirements with maps

identifying standards by applicable categories and international equivalences• Support to identify safety requirements by hazards with

forms • Lists of applicable documents for each phase with templates

and clear approval and distribution processes

The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

EXAMPLE

Coils manufacturing

Nb3Sn strand Nb3Sn cablesElectrical insulation

(Nb3Sn cables)Coils winding

Ceramic-binderinjection

Reaction of Nb3Sn coils

Vacuumimpregnationof Nb3Sn coils

Curing

“Wind & React” process (simplified)

Instrumentation(Quench/spot heatersTemperature sensors

Voltage tapsStrain gauges)

Splices Final assembly(insulation films and

quench heaters)

Based on USPAS lectures (courtesy E. Todesco)

Conducting materials Insulating materials

Soldering

Magnetic materials

Cold Mass assembly

CollarsIron yoke Shell End plates

Cold bore tube and beam screen

Note: shell + end plates + cold bore tube define the He II (atmospheric pressure) containment vessel

Based on USPAS lectures (courtesy E. Todesco) & LHC Design Report (Vol. I)

He II heat exchanger tube

Magnets system- Standards architecture

* based on the International Classification of Standards (ICS)

A non-exhaustive overview of some applicable fields and their corresponding groups and sub-groups*

Coils manufacturing

Electrical engineering

Conducting materials

Insulating materials

Magnetic materials

Rubber and plastic industries

Rubber and plastics products

Plastics

Metallurgy

Products of non-ferrous metals

Copper products

Testing of metals

Mechanical testing of metals

Non-destructive testing of metals

Manufacturing engineering

Welding, brazing and soldering

Brazing and soldering

Welding processes

Welded joints

Magnets system- Standards architecture

* based on the International Classification of Standards (ICS)

A non-exhaustive overview of some applicable fields and their corresponding groups and sub-groups*

Cold mass assembly

Metallurgy

Testing of metals

Mechanical testing of metals

Non-destructive testing of metals

Iron and steel products

General

Steels for pressure purposes

Electrical engineering

Magnetic materials

Testing

Non-destructive testing

EXAMPLESStandards Maps

Superconductivity and conducting materials

Magnetic materials

Brazing and soldering

Mechanical testing of metals